Sewing machine

ABSTRACT

An embroidery sewing machine includes a needle, a needle driving section which vertically drives the needle, a cloth holding section which holds a cloth, a moving section which moves the cloth holding section along a plane, a storage section, an array calculating section and a control section. The array calculating section arranges a plurality of outlines of the piece in the sewing enabling region based on the cutting line data and the region data that are stored in the storage section, and obtains array data representing each arrangement position of the outlines of the piece and each rotating angles of the outlines of the piece in respective arrangement positions. The control section controls the moving section and the needle driving section in accordance with the array data and the cutting line data so as to form a cutting line of a seam on the cloth.

The present invention claims foreign priority from Japanese patent application no. 2005-334597 filed on Nov. 18, 2005, the content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a sewing machine which supports creating pieces for a patchwork.

When carrying out a patchwork, a pattern to be created is designed, and shapes, sizes and colors of cloth pieces referred to as pieces which constitute the pattern are determined. These pieces are joined to each other, thereby forming the designed pattern. In recent years, there has been developed an apparatus which edits and creates a pattern of a patchwork by using a computer (see, e.g., JP-A-8-134765).

Before carrying out the patchwork, it is necessary to create a piece to be a material. For this reason, an operator uses a chalk to draw a line on a cloth and cuts the cloth along the line, thereby creating a piece.

However, the number of pieces to constitute a pattern of the patchwork is enormous and a great deal of time and labor is required for creating each of the pieces by drawing a line on a cloth.

SUMMARY OF THE INVENTION

Therefore, the present invention has been made in order to solve the problem, and it is an object of the present invention to provide a sewing machine which supports an operator in creating pieces so that a large number of pieces can be easily created in a short time.

According to a first aspect of the invention, A sewing machine includes: a needle; a needle driving section which vertically drives the needle; a cloth holding section which holds a cloth; a moving section which moves the cloth holding section along a plane; a storage section which stores cutting line data representing an outline of a piece and region data representing a sewing enabling region through the cloth holding section; an array calculating section which arranges a plurality of outlines of the piece in the sewing enabling region based on the cutting line data and the region data that are stored in the storage section, and obtains array data representing each arrangement position of the outlines of the piece and each rotating angles of the outlines of the piece in respective arrangement positions; and a control section which controls the moving section and the needle driving section in accordance with the array data obtained by the array calculating section and the cutting line data stored in the storage section. The moving section and the needle driving section form a cutting line of a seam on the cloth such that at least a part of one or more outlines of the piece according to the cutting line data are arranged along the cutting line of the seam in accordance with the array data.

Therefore, when the operator cuts the cloth along the cutting line, it is possible to create a plurality of pieces. More specifically, it is possible to save troubles for drawing a line on the cloth for each of the outlines of the pieces. Consequently, the operator can easily create the pieces in a short time.

According to a second aspect of the invention, the sewing machine may further include a selecting section which selects a type of the piece from a plurality of types of pieces, wherein the storage section stores the cutting line data on respective types of pieces, and the array calculating section obtains the array data based on the cutting line data corresponding to the type of the piece selected by the selecting section.

Therefore, when the control means controls the needle driving means and the moving means in accordance with the cutting line data and the array data, the seam to be formed on the cloth is set in a state in which the outlines of the selected piece are arranged in accordance with the array data. Accordingly, it is possible to create pieces of various outlines by the selection of the selecting means.

According to a third aspect of the invention, the sewing machine may further include a setting section which sets a number of pieces, wherein the control section controls the moving section and the needle driving section in accordance with the arrangement positions and the rotating angles of the outlines of set number of pieces set by the setting section, from the array data obtained by the array calculating section. Therefore, the seam to be formed on the cloth is brought into a state in which the outlines of set number of pieces set by the setting means are arranged in accordance with the array data. Accordingly, it is possible to set the number of pieces to be created.

According to a fourth aspect of the invention, the sewing machine may further include a display section, on which the plurality of outlines of the piece arranged in the sewing enabling region are displayed in accordance with the array data.

According to a fifth aspect of the invention, the sewing machine may further include a touch panel, from which the type of the piece to be selected by the selecting section is input.

According to a sixth aspect of the invention, a whole outline of the piece is arranged along the cutting line of the seam.

According to a seventh aspect of the invention, the sewing machine may further include an embroidery frame sensor, wherein the cloth holding section includes an embroidery frame, the embroidery frame sensor detects a type of the embroidery frame, and the array calculating section arranges the plurality of outlines of the piece in the sewing enabling region based on the region data that corresponds to the type of the embroidery frame detected by the embroidery frame sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages, nature, and various additional features of the invention will appear more fully upon consideration of the exemplary embodiments. The exemplary embodiments are set forth in the following drawings.

FIG. 1 is a front view showing an embroidery sewing machine according to a first embodiment of the invention;

FIG. 2 is a block diagram showing a structure of the embroidery sewing machine;

FIG. 3 is a diagram for explaining array data on an equilateral triangular piece;

FIG. 4 is a flowchart showing a processing to be carried out by a microcomputer provided in the embroidery sewing machine;

FIG. 5 is a view showing a selecting screen to be displayed on an operation panel provided in the embroidery sewing machine;

FIGS. 6A to 6D are views for explaining an algorithm for arranging a plurality of pieces;

FIGS. 7A and 7B are views showing layout screens to be displayed on the operation panel;

FIGS. 8A and 8B are views showing cutting lines to be sewn by the embroidery sewing machine;

FIGS. 9A and 9B are views showing states in which a cloth is cut along the cutting line sewn by the embroidery sewing machine;

FIG. 10 is a flowchart showing a processing to be carried out by a microcomputer provided in an embroidery sewing machine according to a second embodiment to which the invention is applied; and

FIG. 11 is a view showing an input screen to be displayed on an operation panel of the embroidery sewing machine according to the second embodiment.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Hereinafter, exemplary embodiments of the invention will be explained with reference to the drawings, the following exemplary embodiments do not limit the scope of the invention.

Embodiment 1

(Structure of Embroidery Sewing Machine)

As shown in FIGS. 1 and 2, an embroidery sewing machine 1 has a bed portion 11 positioned in a lower part, a drum portion 12 provided upward from one end of the bed portion 11, and an arm portion 13 extending along the bed portion 11 from an upper part of the drum portion 12.

Moreover, the embroidery sewing machine 1 includes a needle 14 supported to be vertically movable below a sewing machine head portion 13 a (a left end in FIG. 1) to be a tip side of the arm portion 13, a needle driving mechanism 15 provided in a lower part of the sewing machine head portion 13 a of the arm portion 13 and serving to support the needle 14 and to vertically drive the needle 14, a cloth presser 16 supported on the needle driving mechanism 15 together with the needle 14 and moved vertically together with the needle 14 in an embroidery sewing operation, an embroidery frame 17 disposed below the needle 14 and serving to hold a cloth in a stretching state along a perpendicular plane with respect to the needle 14, a frame moving mechanism 18 provided in an opposed position to the bed portion 11 and serving to drive the embroidery frame 17 along a perpendicular plane to the needle 14, and an operation panel 5 for inputting an instruction and setting related to an operation of the embroidery sewing machine 1 and displaying necessary information for the instruction and a current state.

The sewing machine head portion 13 a on a left end of the arm portion 13 shown in FIG. 1 includes a starting/stop switch for starting/stopping a sewing operation (which will be hereinafter referred to as an S/S switch) 20, a reverse stitch switch 21 for inputting an instruction to carry out a reverse sewing operation, a thread cutting switch 22 for inputting an instruction for cutting a thread after the sewing operation, and a slide volume 23 for regulating a speed of the sewing operation which are arranged in order from a bottom.

Moreover, the embroidery sewing machine 1 comprises a microcomputer 6 serving to control the needle driving mechanism 15, the frame moving mechanism 18 and the operation panel 5 and to input a signal from the operation panel 5, the S/S switch 20, the reverse stitch switch 21, the thread cutting switch 22, and the slide volume 23, and a storage portion 63 for storing a program and data which can be read by the microcomputer 6.

Assuming that a direction in which the needle 14 carries out a vertical motion is set to be a Z-axis direction, a direction in which the embroidery frame 17 is moved in a transverse direction in FIG. 1 by means of the frame moving mechanism 18 (one of two perpendicular directions to each other) is set to be an X-axis direction, and a direction in which the embroidery frame 17 is moved in a longitudinal direction in FIG. 1 by means of the frame moving mechanism 18 (the other of the two perpendicular directions to each other) is set to be a Y-axis direction, the following description will be given.

(Needle Driving Mechanism)

The needle driving mechanism 15 includes a sewing machine motor 24 to be a driving source (which is shown in FIG. 2) and a crank mechanism for converting a rotating output of the sewing machine motor 24 into a vertical motion of the needle 14. A timing for operating/stopping the sewing machine motor 24 is controlled by the microcomputer 6, and furthermore, a rotating speed of the sewing machine motor 24 is controlled by the microcomputer 6 so that a cycle of the vertical motion of the needle 14 is controlled. Moreover, the microcomputer 6 serves to control the rotating speed of the sewing machine motor 24 in accordance with setting of the slide volume 23.

(Embroidery Frame)

The embroidery frame 17 to be cloth holding means is constituted by an outer frame taking an almost rectangular shape and an inner frame forming an almost rectangle and capable of being fitted in the outer frame in the same manner. A cloth is interposed between the inner frame and the outer frame in a stretching state over the inner frame, and a plane region taking an almost rectangular shape in the cloth is formed on an inside of the frame and serves as a sewing enabling region. Moreover, embroidery frames having three sizes, that is, large, middle and small sizes can be selectively attached. The sewing enabling region is determined every size of the embroidery frame and the embroidery frame 17 shown in the drawing has a maximum size.

(Frame Moving Mechanism)

The frame moving mechanism 18 to be moving means includes a carriage 25 supported to be reciprocable in the X-axis direction over an upper surface of the bed portion 11, an X-axis motor 26 (shown in FIG. 2) for driving the carriage 25 in the X-axis direction, an embroidery frame attaching portion 27 supported on the carriage 25 so as to be reciprocable in the Y-axis direction, and a Y-axis motor 28 (see FIG. 2) for driving the embroidery frame 17 in the Y-axis direction through the embroidery frame attaching portion 27. Moreover, the frame moving mechanism 18 is provided to freely convert a rotating output of the X-axis motor 26 into a power in a direct moving direction of the carriage 25, and furthermore, is provided to freely convert a rotating output of the Y-axis motor 28 into a power in a direct moving direction of the embroidery frame attaching portion 27. Accordingly, the frame moving mechanism 18 freely moves the embroidery frame 17 along an X-Y plane (an orthogonal plane to the needle 14) by a cooperation of the movement of the carriage 25 and that of the embroidery frame attaching portion 27. A certain position on the X-Y plane over which the embroidery frame 17 is moved is represented by an X-Y coordinate system determined by X and Y axes which are orthogonal to each other.

Moreover, both the X-axis motor 26 and the Y-axis motor 28 are stepping motors and can control a rotating angle for driving on a very small angle unit. A timing for operating/stopping each of the motors 26 and 28 is controlled by the microcomputer 6. Furthermore, a rotating speed of each of the motors 26 and 28 is controlled by the microcomputer 6. More specifically, the rotating angle of each of the motors 26 and 28 per vertical motion of the needle 14 is controlled by the microcomputer 6. Consequently, the embroidery frame 17 is moved in each axial direction and a relative needle location of the needle 14 is determined.

In addition, the embroidery frame attaching portion 27 is provided with an embroidery frame sensor 29 (shown in FIG. 2). The embroidery frame sensor 29 detects a size (type) of the embroidery frame attached to the embroidery frame attaching portion 27. In the case in which the embroidery frame 17 having the maximum size is attached to the embroidery frame attaching portion 27, a signal indicative of the maximum size is output from the embroidery frame sensor 29 to the microcomputer 6. In the case in which the embroidery frame having the middle size is attached to the embroidery frame attaching portion 27, a signal indicative of the middle size is output from the embroidery frame sensor 29 to the microcomputer 6. In the case in which the embroidery frame having the minimum size is attached to the embroidery frame attaching portion 27, a signal indicative of the minimum size is output from the embroidery frame sensor 29 to the microcomputer 6.

(Operation Panel)

As shown in FIG. 2, the operation panel 5 includes a liquid crystal display 51 for carrying out a display in accordance with a display signal of the microcomputer 6 and a touch panel 52 to be a transparent pressure-sensitive switch provided in a superposition on a display surface of the liquid crystal display 51. In the case in which a finger of an operator touches the surface of the touch panel 52, a contact position thereof is detected by the touch panel 52 so that the touch panel 52 outputs, to the microcomputer 6, an operation signal corresponding to the contact position. The liquid crystal display 51 displays various switches (icons) in an operating screen in accordance with the display signal of the microcomputer 6. Accordingly, the microcomputer 6 recognizes which position is touched upon receipt of the output of the touch panel 52, and furthermore, collates whether such operation input corresponds to any of the switches displayed on the liquid crystal display 51. As a result, which operation is being carried out by the operator is recognized.

(Storage Portion)

The storage portion 63 has a magnetic storage medium, an optical storage medium or a semiconductor memory, and a program and data are prestored in the magnetic storage medium, the optical storage medium or the semiconductor memory. The program stored in the storage portion 63 is stored in a configuration of a program code which can be read by the microcomputer 6 and an operation in accordance with the program code is successively executed under a control of the microcomputer 6.

The data to be stored in the storage portion 63 include cutting line data and sewing data which correspond to respective types of pieces. One cutting line data and one sewing data correspond to one type of pieces. The type of pieces includes a piece having a shape of an equilateral triangle, a piece having a square shape, a piece having a rectangular shape, a piece having a shape of a parallelogram, a piece having a shape of a right triangle, and a piece having a shape of a rectangular equilateral triangle. All of the types have outlines forming closed curves. The cutting line data defines the outline of the piece corresponding to the cutting line data by a u-v coordinate system of u and v axes which are orthogonal to each other. The cutting line data includes a sewing start position in the u-v coordinate system and a data string in which the amounts of movement per respective stitches are arranged corresponding to the number of needle locations. The amount of a movement per stitch is expressed in a moving amount Δu in a u direction and a moving amount Δv in a v direction in the u-v coordinate system. Moreover, the sewing data is data for moving the embroidery frame 17 in the X-Y directions every stitch during a sewing mode in which the cutting line data is not used, in order to form a seam on the inside of the outline of the piece along the outline.

When the microcomputer 6 controls the sewing machine motor 24, the X-axis motor 26 and the Y-axis motor 28 in accordance with the cutting line data, a cutting line (a seam) of the outline of the piece corresponding to the cutting line data is formed on a cloth.

Moreover, the data to be stored in the storage portion 63 includes region data which correspond to respective types of the embroidery frame. The region data represent a sewing enabling region of the embroidery frame corresponding to the region data.

(Microcomputer)

The microcomputer 6 is a control device including a CPU (Central Processing Unit) and an RAM (Random Access memory). The microcomputer 6 carries out a processing in accordance with the program stored in the storage portion 63, controls the needle driving mechanism 15, the frame moving mechanism 18 and the operation panel 5. Further, signals from the operation panel 5, the S/S switch 20, the reverse stitch switch 21, the thread cutting switch 22 and the slide volume 23 are input to the microcomputer 6.

The microcomputer 6 functions as follows in accordance with the program stored in the storage portion 63. In other words, the microcomputer 6 functions as selecting means for displaying plural types of pieces on the liquid crystal display 51 of the operation panel 5 and selecting one of the plural types of pieces in response to an operation signal input from the touch panel 52 of the operation panel 5. Moreover, the microcomputer 6 functions as means for recognizing the size of the embroidery frame attached to the embroidery frame attaching portion 27 based on a signal input from the embroidery frame sensor 29. Moreover, the microcomputer 6 functions as reading means for reading cutting line data corresponding to the piece of the selected type from the storage portion 63 and reading region data corresponding to an embroidery frame having the recognized size.

Moreover, the microcomputer 6 functions as array calculating means for arranging the outline of the piece in the sewing enabling region based on the cutting line data and the region data which are thus read and obtaining array data indicative of an arrangement position of each piece and a rotating angle in the arrangement position. The array data represent the arrangement position of each piece in the X-Y coordinate system and the rotating angle of the piece in the arrangement position. The arrangement position is expressed in the X-Y coordinate system determined by the X and Y axes and the rotating angle is expressed in a matrix M of a linear transformation in which the piece is rotated by the rotating angle. Accordingly, a reference point of the piece (a predetermined point expressed in the u-v coordinate system (for example, an origin of the u-v coordinate system, a sewing start position, or a center of gravity)) can be disposed in the X-Y coordinate system depending on the arrangement position of the array data and moving amounts ΔX and ΔY per stitch in the X-Y coordinate system are calculated by an inner product of the matrix M and the moving amounts Δu and Δv. For example, in case of the piece taking the shape of an equilateral triangle, if an X-Y coordinate of a reference point P1 of an equilateral triangular piece 201 is set to be (0, 0) and a rotating angle thereof is set to be zero degree as shown in FIG. 3, an X-Y coordinate of a reference point P2 of an equilateral triangular piece 202 is (X2, Y2) and a rotating angle is 180 degrees, an X-Y coordinate of a reference point P3 of an equilateral triangular piece 203 is (X3, Y3) and a rotating angle is zero degree, an X-Y coordinate of a reference point P4 of an equilateral triangular piece 204 is (X4, Y4) and a rotating angle is 180 degrees, an X-Y coordinate of a reference point P5 of an equilateral triangular piece 205 is (X5, Y5) and a rotating angle is zero degree, and an X-Y coordinate of a reference point P6 of an equilateral triangular piece 206 is (X6, Y6) and a rotating angle is 180 degrees.

The arrangement position of each piece may be represented by an absolute position (X, Y) in the X-Y coordinate system and may be represented by a difference (ΔX, ΔY) from the arrangement position of an adjacent piece. In the case in which the arrangement position of each piece is represented by a relative position based on the difference, the arrangement position of at least one piece is represented by an absolute position.

Moreover, the microcomputer 6 functions as display control means for carrying out a display on the liquid crystal display 51 in order to arrange the selected type of pieces in accordance with the array data which are obtained. Moreover, the microcomputer 6 functions as control means for controlling the sewing machine motor 24, the X-axis motor 26 and the Y-axis motor 28 in accordance with the cutting line data which are read and the array data which are obtained.

(Operation of Embroidery Sewing Machine)

Next, description will be given to an operation of the embroidery sewing machine 1.

An operator sets a cloth onto the embroidery frame. When the operator starts the broidery sewing machine 1, the microcomputer 6 reads the program stored in the storage portion 63 and carries out a processing as shown in a flowchart of FIG. 4 in accordance with the program.

First of all, the microcomputer 6 outputs a display signal to the liquid crystal display 51 and the liquid crystal display 51 carries out a display operation in accordance with the display signal so that icons for plural types of pieces are displayed on the liquid crystal display 51 (Step S1). For example, as shown in FIG. 5, there are displayed, on the liquid crystal display 51, an icon 91 for an equilateral triangular piece, an icon 92 for a square piece, an icon 93 for a rectangular piece, an icon 94 for a piece taking a shape of a parallelogram, an icon 95 for a right triangular piece, and an icon 96 for a rectangular equilateral triangular piece.

When the operator determines one of the plural types of pieces which are displayed and touches the surface of the touch panel 52 over the piece of the type which is determined by the operator, a contact position is detected by the touch panel 52 and an operation signal corresponding to the contact position is output from the touch panel 52 to the microcomputer 6. In response to the operation signal, one of the plural types of pieces is selected by the microcomputer 6 (Step S2).

Next, the size of the embroidery frame is detected by the embroidery frame sensor 29 and a signal indicative of the size of the embroidery frame is output to the microcomputer 6, and the microcomputer 6 recognizes the size of the embroidery frame (Step S3).

Then, the microcomputer 6 reads, from the storage portion 63, cutting line data corresponding to the piece of the type which is selected, and furthermore, reads region data corresponding to the embroidery frame having the size which is detected (Step S4).

Thereafter, the microcomputer 6 arranges an outline (cutting line) of the piece in the sewing enabling region based on the cutting line data and the region data and obtains array data representing the arrangement position of each piece and a rotating angle in the arrangement position (Step S5). For example, in the case in which the operator determines the icon 92 for a square piece at the Step S2, the microcomputer 6 disposes a first square piece 82 on a left upper part in a sewing enabling region 81 as shown in FIG. 6A, and second and succeeding square pieces 82 are arranged to come in contact with each other without a clearance as shown in FIG. 6B. The piece has a peculiar size. Therefore, the microcomputer 6 calculates a quotient (an integer part) obtained by dividing a length in a transverse direction of the sewing enabling region 81 by a length in a transverse direction of the square piece 82 and arranges the square pieces 82 rightward corresponding to the number of the square pieces 82 which can be disposed in a rightward direction (the integer part of the quotient which is calculated). As shown in FIG. 6C, the microcomputer 6 arranges the square piece 82 up to a right end in the sewing enabling region 81. Then, the same square piece 82 is also arranged for a next row. Such a processing is repeated so that the square piece 82 is arranged in the sewing enabling region 81 as shown in FIG. 6D. Thereafter, the microcomputer 6 obtains array data representing the arrangement positions and rotating angles of the respective square pieces 82.

Subsequently, the microcomputer 6 displays, on the liquid crystal display 51, a screen in which the selected type of pieces are arranged in accordance with the array data (Step S6). For example, in the case in which the operator determines the icon 92 for a square piece at the Step S2, a plurality of square pieces 102 is displayed on the liquid crystal display 51 in a state in which they are arranged in a sewing enabling region 103 as shown in FIG. 7A. In the case in which the operator determines the icon 96 for a rectangular equilateral triangular piece at the Step S2, a plurality of rectangular equilateral triangular pieces 106 is displayed on the liquid crystal display 51 in a state in which they are arranged in the sewing enabling region 103 as shown in FIG. 7B.

Next, the microcomputer 6 operates the sewing machine motor 24, the X-axis motor 26 and the Y-axis motor 28 and controls the sewing machine motor 24, the X-axis motor 26 and the Y-axis motor 28 in accordance with the cutting line data which are read and the array data which are obtained (Step S7). Consequently, the needle 14 carries out a vertical motion, the embroidery frame 17 is moved along the X-Y plane, a cutting line (a seam) to be the outline of the piece is sequentially formed on a cloth every piece, and the cutting line is provided in a state in which the outline of the piece in accordance with the cutting line data is arranged in accordance with the array data. For example, in the case in which the operator determines the icon 92 for a square piece at the Step S2, a cutting line 112 in a state in which a plurality of square pieces is arranged is sewn onto a cloth 110 in the embroidery frame 17 as shown in FIG. 8A. In the case in which the operator determines the icon 96 for a rectangular equilateral triangular piece at the Step S2, a cutting line 116 in a state in which a plurality of triangular pieces is arranged is sewn onto the cloth 110 in the embroidery frame 17 as shown in FIG. 8B.

After the cutting line is formed on the cloth by the embroidery sewing machine 1, the operator removes the cloth from the embroidery frame 17. Then, the operator can create a plurality of pieces by cutting the cloth along the cutting line of the cloth. For example, when the cloth 110 shown in FIG. 8A is cut, a plurality of square pieces 122 can be created as shown in FIG. 9A. When the cloth 110 shown in FIG. 8B is cut, a plurality of triangular pieces 126 can be created as shown in FIG. 9B.

After creating the pieces as described above, one side of a piece and one side of another piece are overlapped with each other and are sewn together, and such work is repeated so that a cloth piece having a desirable size is made.

As described above, according to the first embodiment, the cutting line in the state in which the outlines of the pieces are arranged is formed on the cloth by the embroidery sewing machine 1. Therefore, it is possible to eliminate a great deal of time and labor required for drawing a line on the cloth along each of the outlines of the pieces. By cutting the cloth along the cutting line, consequently, the operator can easily create a plurality of pieces in a short time.

Moreover, the operator can determine an optional type of pieces through the display screen at the Step S1, and the microcomputer 6 selects the type determined by the operator and reads the cutting line data corresponding to the piece of the selected type from the storage portion 63. Therefore, the cutting line of the seam formed on the cloth is set into a state in which the outlines of the selected pieces are arranged in accordance with the array data. Accordingly, the operator can create an optional type of pieces.

Embodiment 2

Next, description will be given to an embroidery sewing machine according to a second embodiment of the invention. Referring to the embroidery sewing machine according to the second embodiment, the same portions as those in the embroidery sewing machine 1 according to the first embodiment have the same reference numerals and only different portions will be described.

A microcomputer 6 functions as follows depending on a program stored in a storage portion 63. In other words, the microcomputer 6 functions as selecting means for displaying plural types of pieces on a liquid crystal display 51 of an operation panel 5 and selecting one of the plural types of pieces in response to an operation signal input from a touch panel 52 of the operation panel 5. Moreover, the microcomputer 6 functions as means for recognizing a size of an embroidery frame attached to an embroidery frame attaching portion 27 in response to a signal input from an embroidery frame sensor 29. Furthermore, the microcomputer 6 functions as reading means for reading cutting line data corresponding to the piece of the selected type from the storage portion 63 and reading region data corresponding to an embroidery frame having the recognized size. In addition, the microcomputer 6 functions as array calculating means for arranging an outline of the piece in a sewing enabling region based on the cutting line data and the region data which are thus read and obtaining array data indicative of an arrangement position of each piece and a rotating angle in the arrangement position. Furthermore, the microcomputer 6 functions as setting means for displaying an input screen for a numerical value (a natural number) on the liquid crystal display 51 of the operation panel 5 and setting the number of pieces in response to an operation signal input from the operation panel 5. In addition, the microcomputer 6 functions as display control means for carrying out a display on the liquid crystal display 51 in order to arrange the selected type of pieces in accordance with the positions and rotating angles of the number of pieces which is set in the array data which are obtained. Moreover, the microcomputer 6 functions as control means for controlling a sewing machine motor 24, an X-axis motor 26 and a Y-axis motor 28 in accordance with the positions and rotating angles of the number of pieces which is set in the array data which are obtained and the cutting line data which are read.

Description will be given to an operation of the embroidery sewing machine according to the second embodiment.

An operator sets a cloth onto an embroidery frame 17. When the operator starts an embroidery sewing machine 1, the microcomputer 6 reads the program stored in the storage portion 63 and carries out a processing as shown in a flowchart of FIG. 10 in accordance with the program.

First of all, the microcomputer 6 outputs a display signal to the liquid crystal display 51 so that icons for plural types of pieces are displayed on the liquid crystal display 51 (Step SA1). When the operator touches the surface of the touch panel 52 over the piece of the type which is determined by the operator, an operation signal corresponding to a contact position is output from the touch panel 52 to the microcomputer 6 and one of the plural types of pieces is selected by the microcomputer 6 in response to the operation signal (Step SA2). Next, the size of the embroidery frame is detected by the embroidery frame sensor 29 and the microcomputer 6 recognizes the size of the embroidery frame in response to the signal of the embroidery frame sensor 29 (Step SA3). Next, the microcomputer 6 reads, from the storage portion 63, the cutting line data corresponding to the piece of the type which is selected, and furthermore, reads region data corresponding to the embroidery frame having the size which is detected (Step SA4). Then, the microcomputer 6 arranges an outline of the piece in the sewing enabling region based on the cutting line data and the region data and obtains array data representing an arrangement position of each piece and a rotating angle in the arrangement position (Step SA5). The processings of the Steps SA1, SA2, SA3, SA4 and SA5 are the same as those of the Steps S1, S2, S3, S4 and S5 in the first embodiment, respectively.

Subsequently, the microcomputer 6 outputs a display signal to the liquid crystal display 51 and the liquid crystal display 51 carries out a display operation in accordance with the display signal so that an input screen for inputting the number of pieces is displayed on the liquid crystal display 51 (Step SA6). When the operator inputs the number of the pieces through the touch panel 52, then, an operation signal corresponding to a contact position is output from the touch panel 52 to the microcomputer 6 and the number of the pieces is set by the microcomputer 6 in response to the operation signal (Step SA7).

The processings of the Steps SA6 and SA7 will be specifically described. At the Step SA6, a screen shown in FIG. 11 is displayed on the liquid crystal display 51. In the screen of FIG. 11, a piece number display portion 151, a plus icon 152, a minus icon 153 and a determination icon 154 are displayed on the liquid crystal display 51 by the microcomputer 6. The microcomputer 6 causes the piece number display portion 151 to display a numerical value (a natural number). Every time the touch panel 52 is touched in the display portion of the plus icon 152, the microcomputer 6 gradually increases the numerical value of the piece number display portion 151 by one. Every time the touch panel 52 is touched in the display portion of the minus icon 153, the microcomputer 6 gradually decreases the numerical value of the piece number display portion 151 by one. When the touch panel 52 is touched in the display portion of the determination icon 154, the microcomputer 6 sets, as the number of the pieces, the numerical value displayed on the piece number display portion 151 (Step SA7).

Next, the microcomputer 6 displays, on the liquid crystal display 51, a screen in which the selected type of pieces are arranged in accordance with the array data (Step SA8). At the Step SA8, the microcomputer 6 displays, on the liquid crystal display 51, a screen in which the number of pieces which is set at the Step SA7 in the obtained array data are arranged.

Next, the microcomputer 6 operates the sewing machine motor 24, the X-axis motor 26 and the Y-axis motor 28 and controls the sewing machine motor 24, the X-axis motor 26 and the Y-axis motor 28 in accordance with the cutting line data which are read and the array data which are obtained (Step SA9). Consequently, a needle 14 carries out a vertical motion, the embroidery frame 17 is moved along an X-Y plane, a cutting line (a seam) to be the outline of the piece is sequentially formed on a cloth every piece corresponding to the set number, and the cutting line is provided in a state in which the outline of the piece in accordance with the cutting line data is arranged in accordance with the array data. After the cutting line is formed on the cloth by the sewing machine 1, the operator removes the cloth from the embroidery frame 17. Then, the operator can create a plurality of pieces by cutting the cloth along the cutting line of the cloth.

Also in the second embodiment, the cutting line in the state in which the outlines of the pieces are arranged is sewn onto the cloth by the embroidery sewing machine 1. Therefore, it is possible to eliminate a great deal of time and labor required for drawing a line on the cloth along each of the outlines of the pieces and to easily create a plurality of pieces in a short time.

Moreover, the operator can optionally determine the number of the pieces through the input screen in the Step SA6, and the cutting line created by the embroidery sewing machine serves to arrange the outlines of the determined number of pieces. Accordingly, the operator can create the optional number of pieces.

In the above-described exemplary embodiments, the operator touches the touch panel 52, thereby inputting the number of the pieces and the type of the pieces. However, it is also possible to input the number and type of the pieces by using other input devices (for example, a keyboard and a mouse) in place of the touch panel 52.

Moreover, it is also possible to sew a part of the outline of the piece (for example, four apexes in case of a square piece) without sewing the whole outline of the piece as a cutting line. In other words, the cutting line data may represent a part of the outlines of the pieces.

While there has been described in connection with the exemplary embodiments of the present invention, it will be obvious to those skilled in the art that various changes and modification may be made therein without departing from the present invention. It is aimed, therefore, to cover in the appended claim all such changes and modifications as fall within the true spirit and scope of the present invention. 

1. A sewing machine comprising: a needle; a needle driving section which vertically drives the needle; a cloth holding section which holds a cloth; a moving section which moves the cloth holding section along a plane; a storage section which stores cutting line data representing an outline of a piece and region data representing a sewing enabling region through the cloth holding section; an array calculating section which arranges a plurality of outlines of the piece in the sewing enabling region based on the cutting line data and the region data that are stored in the storage section, and obtains array data representing each arrangement position of the outlines of the piece and each rotating angles of the outlines of the piece in respective arrangement positions; and a control section which controls the moving section and the needle driving section in accordance with the array data obtained by the array calculating section and the cutting line data stored in the storage section, wherein the moving section and the needle driving section form a cutting line of a seam on the cloth such that at least a part of one or more outlines of the piece according to the cutting line data are arranged along the cutting line of the seam in accordance with the array data.
 2. The sewing machine according to claim 1, further comprising a selecting section which selects a type of the piece from a plurality of types of pieces, wherein the storage section stores the cutting line data on respective types of pieces, and the array calculating section obtains the array data based on the cutting line data corresponding to the type of the piece selected by the selecting section.
 3. The sewing machine according to claim 1, further comprising a setting section which sets a number of pieces, wherein the control section controls the moving section and the needle driving section in accordance with the arrangement positions and the rotating angles of the outlines of set number of pieces set by the setting section, from the array data obtained by the array calculating section.
 4. The sewing machine according to claim 1, further comprising a display section, on which the plurality of outlines of the piece arranged in the sewing enabling region are displayed in accordance with the array data.
 5. The sewing machine according to claim 2, further comprising a touch panel, from which the type of the piece to be selected by the selecting section is input.
 6. The sewing machine according to claim 1, wherein a whole outline of the piece is arranged along the cutting line of the seam.
 7. The sewing machine according to claim 1, further comprising an embroidery frame sensor, wherein the cloth holding section includes an embroidery frame, the embroidery frame sensor detects a type of the embroidery frame, and the array calculating section arranges the plurality of outlines of the piece in the sewing enabling region based on the region data that corresponds to the type of the embroidery frame detected by the embroidery frame sensor. 